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The Hall–Héroult process is the major industrial process for smelting aluminium.It involves dissolving aluminium oxide (alumina) (obtained most often from bauxite, aluminium's chief ore, through the Bayer process) in molten cryolite and electrolyzing the molten salt bath, typically in a purpose-built cell.
A typical smelter contains anywhere from 300 to 720 pots, each of which produces about a ton of aluminium a day, though the largest proposed smelters are up to five times that capacity. Smelting is run as a batch process, with the aluminium deposited at the bottom of the pots and periodically siphoned off.
This is a list of primary aluminium smelters in the world. Primary production is the process by which alumina is smelted to pure aluminum. [1] Secondary production is the process of recycling aluminum scrap into aluminum that can be used again. [2]
It was not until 1978 that conditions improved sufficiently for Comalco to commit in principle to the establishment of the Boyne Island aluminium smelter. In August 1979 Comalco formed the consortium company to establish the smelter. [3] [4] Initially the consortium comprised American and Japanese participants along with Comalco, an Australian ...
The smelter uses the Hall–Héroult process to convert alumina (aluminium oxide) to elemental aluminium. Bauxite is mined in Australia and refined into alumina before being shipped to New Zealand. [17] The smelter consists of three lines of P69 technology cells, with 208 cells each (i.e. 624 total), and one line of 48 CD200 technology cells.
The smelter was commissioned in 1996 [1] and was designed to produce 60,000 t/y of copper (450,000 t/y of copper concentrate), [45] but by increasing the oxygen content of the lance air and making modifications to other equipment, the ISASMELT furnace feed rate was increased to the point where the smelter was producing 180,000 t/y of copper.
The blast furnace used at the Nyrstar Port Pirie lead smelter differs from most other lead blast furnaces in that it has a double row of tuyeres rather than the single row normally used. [76] The lower shaft of the furnace has a chair shape with the lower part of the shaft being narrower than the upper. [ 76 ]
Copper smelter, Chelyabinsk Oblast, Russia Electrolytic cells at an aluminum smelter in Saint-Jean-de-Maurienne, France Smelting involves more than just melting the metal out of its ore. Most ores are the chemical compound of the metal and other elements, such as oxygen (as an oxide ), sulfur (as a sulfide ), or carbon and oxygen together (as a ...